PERFORMANCE MODELING OF AUTOMATED MANUFACTURING SYSTEMS

N. VISWANADHAM
Department of Computer Science and Automation Indian Institute of Science

Y NARAHARI
Department of Computer Science and Automation Indian Institute of Science

PRENTICE HALL, Englewood Cliffs, New Jersey 07632

CONTENTS
PREFACE Chapter 1
1.1 1.1.1 1.1.2 1.2 1.2.1 1.2.2 1.3 1.4

xiii INTRODUCTION
MODELING AUTOMATED MANUFACTURING SYSTEMS Role of Performance Modeling Performance Measures PERFORMANCE MODELING TOOLS Simulation Models Analytical Models ORGANIZATION OF THE BOOK BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY

1
1 2 3 4 4 5 6 9

Chapter 2
2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2

AUTOMATED MANUFACTURING SYSTEMS

INTRODUCTION History of Manufacturing The Product Cycle Manufacturing Automation Economies of Scale and Scope MANUFACTURING SYSTEMS Input-Output Model Plant Configurations PERFORMANCE MEASURES Manufacturing Lead Time Work-in-Process

11
12 12 18 26 28 31 32 34 37 38 45

CONTENTS

2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.6 2.6.1 2.6.2 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.8.5

Machine Utilization Throughput Capacity Flexibility Performability Quality COMPUTER-CONTROLLED MACHINES . Numerically Controlled Machines . . . . . Pallets and Fixtures Machine Centers Automated Inspection Systems MATERIAL HANDLING SYSTEMS Introduction Conveyors Industrial Robots Automated Guided Vehicles PLANT LAYOUT Group Technology Some Typical Layouts

46 47 47 48 49 52 55 55 57 59 67 72 72 75 78 83 95 96 97

FLEXIBLE MANUFACTURING SYSTEMS 102 Architecture of FMS 102 Automated Workpiece Flow 105 Automated Assembly Systems 109 Deadlocks in Automated Manufacturing Systems 115 Performance Measures 118 COMPUTER CONTROL SYSTEMS Control System Architecture Factory Communications Local Area Networks Factory Networks Open Systems Interconnection Model . . 125 125 131 133 140 142

CONTENTS

vii

2.8.6 2.8.7 2.8.8 2.9

Network to Network Interconnections . . 146 Manufacturing Automation Protocol . . . 149 Database Management System 151 BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 155

Chapter 3
3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.5 3.5.1

MARKOV CHAIN MODELS

163

MEMORYLESS RANDOM VARIABLES . 164 Geometrie Random Variable 164 Exponential Random Variable 167 STOCHASTIC PROCESSES IN MANUFACTURING Examples of Stochastic Processes . . . . Poisson Process 171 172 173

DISCRETE TIME MARKOV CHAIN MODELS 179 Definitions and Notation 180 Sojourn Times in States 182 Examples of DTMCs in Manufacturing . 182 Chapman-Kolmogorov Equation 188 Steady-State Analysis 192 CONTINUOUS TIME MARKOV CHAIN MODELS 206 Definitions and Notation 206 Sojourn Times in States 207 Examples of CTMCs in Manufacturing . 209 Equations for CTMC Evolution 215 Analysis of Homogeneous CTMCs . . . 218 Embedded Markov Chain in CTMCs . . 232 AN EXAMPLE: MARKOV MODEL OF A TRANSFER LINE 239 Rate Balance Equations 240

viii

CONTENTS

3.5.2 3.5.3 3.6 3.6.1 3.6.2 3.7 3.7.1 3.7.2 3.8 3.8.1 3.8.2 3.8.3 3.9 3.9.1 3.9.2 3.9.3 3.10 3.10.1 3.10.2 3.11 3.11.1 3.11.2 3.11.3

Steady-State Analysis Performance Evaluation

242 243

BIRTH AND DEATH PROCESSES IN MANUFACTURING 246 Steady-State Analysis of BD Processes . 247 Typical BD Processes in Manufacturing 248 TIME REVERSIBLE MARKOV CHAINS IN MANUFACTURING 254 Time Reversible DTMCs 255 Time Reversible CTMCs 258 ABSORBING STATES AND MODELING OF DEADLOCKS 263 Examples of Absorbing States 264 Analysis of Markov Chains with Absorbing States 268 Application to Examples 272 SEMI-MARKOV PROCESSES IN MANUFACTURING 276 Definition and Examples 277 Analysis of Semi-Markov Processes . . . 278 Application to Examples 279 TRANSIENT ANALYSIS OF MANUFACTURING SYSTEMS 283 Solution of Forward and Backward Equations 283 Distribution of Time to Deadlock . . . . 288 COMPUTATIONAL ISSUES IN MARKOV ANALYSIS Computational Issues in Steady-State Analysis Solution Methods for Steady-State Analysis Time Scale Analysis Technique 293 293 295 297

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ix

3.11.4 3.11.5 3.12

Computational Issues in Transient Analysis Uniformization BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY

301 303 307

Chapter 4
4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 4.5 4.5.1 4.5.2 4.5.3 4.6 4.6.1 4.6.2

QUEUING MODELS
QUEUES: NOTATION AND EXAMPLES. Notation for Queues Examples of Queues in Manufacturing Systems Performance Measures Little's Result THE M/M/1 QUEUE Steady-State Analysis of the M/M/1 Queue Waiting-Time Distributions The M/M/l/N Queue

315
317 318 319 322 324 326 326 330 333

THE M/M/m QUEUE 336 Steady-State Analysis 337 Departure Process of M/M/m Queue . . 340 BATCH ARRIVAL QUEUING SYSTEMS . 343 QUEUES WITH GENERAL DISTRIBUTIONS The M/G/l Queue The GI/M/1 Queue The GI/G/1 Queue QUEUES WITH BREAKDOWNS Problem Formulation Steady-State Analysis 347 348 355 358 359 359 360

CONTENTS

4.7 4.7.1 4.7.2 4.7.3 4.8 4.8.1 4.8.2 4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.10 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 4.11 4.11.1 4.11.2 4.12 4.12.1 4.12.2

ANALYSIS OF A FLEXIBLE MACHINE CENTER 363 Problem Formulation 364 Performance Measures 365 Analysis for Exhaustive Service and Gated Service 366 QUEUING NETWORKS 369 Examples of QN Models in Manufacturing 370 Little's Law in Queuing Networks . . . . 375 OPEN QUEUING NETWORKS 378 The Tandem Queue 378 An Open Queuing Network with Feedback 382 An Open Central Server Model for FMS 385 Jackson's Network 388 CLOSED QUEUING NETWORKS A Closed Transfer Line The Closed Central Server Model . . . . Gordon-Newell Networks Computation of Normalization Constant Computation of Performance Measures . Mean Value Analysis PRODUCT FORM QUEUING NETWORKS Types of Service Centers Closed Networks with Multiple Job Classes QUEUING NETWORKS WITH BLOCKING Types of Blocking Mechanisms Two-Node Open Network with AS Blocking 394 395 396 399 402 404 407 411 412 414 421 422 423

CONTENTS

xi

4.12.3 4.12.4 4.13 4.13.1 4.13.2 4.13.3 4.14 4.14.1 4.14.2 4.14.3 4.14.4 4.15

Two-Node Closed Network with BAS Blocking 425 Central Server Model with Blocking . . 428 APPROXIMATE ANALYSIS OF QUEUING SYSTEMS 433 Non-Product Form Features in AMSs . . 434 Approximate Analysis Through Aggregation 435 Approximations Employed in the AMS Context 444 PERFORMABILITY ANALYSIS Reliability and Availability Measures . . Performability Measures Machine Center with Infinite Waiting Space Central Server FMS Without Repair . . . BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 446 446 451 453 455 462

Chapter 5
5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.3 5.3.1 5.3.2 5.3.3

PETRI NET MODELS

473

CLASSICAL PETRI NETS 474 Preliminary Definitions 475 Transition Firing and Reachability . . . . 479 Representational Power 481 Properties of Petri Nets 485 STOCHASTIC PETRI NETS Exponential Timed Petri Nets GENERALIZED STOCHASTIC PETRI NETS Definition and Firing Rules Analysis of GSPNs Computation of Performance Measures . 487 489 497 497 502 506

xii

CONTENTS

5.3.4 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.5.2 5.5.3 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.7 5.8

Representational Power of GSPN Models GSPN MODELING OF KANBAN SYSTEMS Description of the System GSPN Model Numerical Results

508 514 515 517 520

DEADLOCK ANALYSIS USING PETRI NETS 524 Deadlock Prevention 526 Deadlock Avoidance 527 Performance Evaluation in the Presence of Deadlocks 537 EXTENDED CLASSES OF TIMED PETRI NETS 542 Colored Stochastic Petri Nets 542 Extended Stochastic Petri Nets 547 Petri Nets with Deterministic and Exponential Firing Times 550 Space of Timed Petri Nets 555 INTEGRATED PFQN-GSPN MODELS . . 559 BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 571

Chapter 6 INDEX

EPILOGUE

581

585